Returnable packaging system for awnings

ABSTRACT

A returnable and reusable shipping and storing system for elongated members, such as rolled awnings. The system includes a cart upon which a series of awning support plates are stacked. Each support plate has a wave-like structure which cooperates with vertically adjacent support plates to define a series of elongated channels. The channels are adapted to slidably receive the rolled awnings, and allow individual rolled awnings to be removed from the stack of support plates regardless of their vertical position within the stack. The awnings project in a cantilever fashion from the support plates, the projecting ends being protected and supported by awning end bags. The awning support plates are nestable to reduce the vertical height required for storage and re-shipment to the awning manufacturer, thereby reducing the inventory and shipping expenses of the system. The end bags preclude the awnings from moving longitudinally, and thereby prevent the awnings from sliding out of the elongated channels during shipment thereof.

BACKGROUND OF THE INVENTION FIELD OF THE INVENTION

The present invention pertains to rolled awnings and, more particularly,to a returnable and reusable packaging and storage system for suchrolled awnings.

DESCRIPTION OF THE RELATED ART

Rolled awnings are conventionally placed in elongated rigid cardboardtubes to protect them during shipment and storage. Although thecardboard tubes are satisfactory to prevent damage to the awnings, thetubes themselves are rather expensive, and insertion of the awnings intothe tubes represents an extra step and additional expense in themanufacture of the awnings. Moreover, since it is undesirable from acost standpoint to return the empty tubes to the manufacturer, the usedcardboard tubes create a disposal problem for the retailer.

From an environmental perspective, the tubes are undesirable as theirmanufacture requires natural resources which are becoming increasinglyexpensive and their disposal takes up much-needed landfill space. Hence,the acquisition and disposal costs of these cardboard tubes, as well astheir burden on the environment, can be expected to increase in thecoming years.

Finally, since the retailer typically purchases a variety of awningshaving different lengths, colors, and fabrics, the cardboard shippingtubes and awnings create an inventory and retrieval problem for theretailer. Namely, when a specific awning is desired for purchase orinspection, the particular cardboard tube containing that awning must belocated within a stack of tubes and thereafter manually pulled orotherwise removed from the stack of awning shipping tubes to gain accessto the desired awning therein. This is not only difficult, but disruptsthe order of the remaining shipping tubes and renders inventory controland awning retrieval problematic.

Therefore, there exists a need in the art for a returnable and reusablerolled awning transport and storage system. There also exists a need inthe art for an awning storage system which permits easy insertion ofawnings therein and removal of awnings therefrom.

SUMMARY OF THE INVENTION

In accordance with the present invention, a reusable and returnablerolled awning transport and storage system is disclosed. The system isadapted to support and maintain the awnings in a rolled condition duringtransport and subsequent storage. The system provides a plurality ofelongated storage spaces which are easily accessible for placement ofawnings therein and removal of awnings therefrom, regardless of therelative vertical position of the storage space.

In further accordance with the present invention, the transport andstorage system includes one or more independently movable and stackablecarts. Each cart is capable of holding and supporting a number of rolledawnings. The system further provides means for protecting ends of therolled awnings which extend or project from the cart in a cantileverfashion and for preventing longitudinal movement of the rolled awnings.The protecting means are operably associated with the cart, and areadjustable to give access to the cantilever ends of the awnings.

In further accordance with the present invention, the packaging andstoring system includes a plurality of nestable and stackable awningsupport plates. The plates are received and vertically supported by thecart and cooperate, when in a stacked configuration, to define a seriesof elongated storage channels for receipt of the awnings. The awningsupport plates vertically support one another such that each rolledawning may be slidably withdrawn from its respective elongated storagechannel regardless of the vertical position of the awning or channelwithin the stack of support plates.

In accordance with the present invention, the awning support platesvertically support each other when in the stacked configuration duringtransport and storage of the rolled awnings. The awning support platesnest with each other to reduce their overall vertical height, which isdesirable for long-term storage of the support plates, or for returnshipment (i.e., without rolled awnings) of the system to the awningmanufacturer.

In accordance with the present invention, the awning support platessupport and protect the individual awnings during transport andsubsequent storage, and remove the need for individual awning protectorssuch as cardboard tubes.

BRIEF DESCRIPTION OF THE DRAWING FIGURES

These and further features of the present invention will be apparentwith reference to the following description and drawings, wherein:

FIG. 1 is a perspective view of the returnable and reusable awningtransport and storage system of the present invention;

FIG. 2 is a front elevational view of an awning transport and storagecart in accordance with the present invention;

FIG. 3 is an cross sectional view of the transport and storage cart inaccordance with the present invention, as viewed from line 3--3 of FIG.2, with rolled awnings placed therein;

FIG. 4 is a top plan view of an awning support plate in accordance withthe present invention;

FIG. 5 is an elevational view of the awning support plate in accordancewith the present invention;

FIG. 6 is an elevational view, in cross section, of the awning supportplate, as viewed from line 6--6 of FIG. 4; and

FIG. 7 is an elevational view, in cross section, of the awning supportplate, as viewed from line 7--7 of FIG. 4.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

With reference to the drawing figures and, in particular, FIGS. 1-3, thereturnable and reusable awning transport and storage system of thepresent invention is shown. The awning transport and storage system isadapted and arranged to allow the safe and protected transport andstorage of a number of rolled awnings 10. Preferably, the rolledawnings, which are adapted for use on residential and commercialbuildings, as well as on travel trailers, mobile homes, motor homes, andthe like, are wrapped or enclosed by a flexible plastic bag (not shown)or other protective material to prevent damage to the awning fromliquids and the like.

The awning transport and storage system generally includes a cart 12, aplurality of awning support plates 14, and a pair of awning end bags orcovers 16. As shown best in FIG. 1, the awning end bags 16 attach toopposite ends of the cart 12, and protect and cover ends 17 of therolled awnings 10 which would otherwise project in an exposed andunprotected manner from the cart 12. The end bags 16 limit axial orlongitudinal movement of the awnings 10 which are otherwise free toslide longitudinally along the support plate 14, as will be describedmore fully hereafter.

With continued reference to FIGS. 1 and 2, the cart 12 is shown toinclude a pair of awning support sections 18 and an intermediate, opensection 20. The awning support sections 18 are adapted to receive andsupport the awning support plates 14 (FIG. 3). The open section 20includes a series of upper and lower horizontal support members 22 and apair of widthwise-directed channels 24.

The upper and lower support members 22 interconnect the awning supportsections 18. The pair of channels 24 are adapted or arranged to receiveforklift forks (not shown) and, preferably, extend the width of the cart12 to allow a forklift to lift the cart from either side. Theintermediate section 20 is open at a top, each end, and each lateralside, as illustrated.

The awning support sections 18 include a bottom panel 26, a pair ofvertical support posts 27, a pair of side panels 28, and a series ofhorizontal support members 29. The awning support sections 18 are openat each end and at a top, as illustrated. The horizontal support members29 vertically support the bottom support panel 26.

Wheels 30 extend downwardly from the awning support sections 18 andallow the cart 12 to be manually pushed or transported, which is helpfulin moving the cart when there is no forklift available or when movingwith a forklift is not feasible.

A vertical leg 32 is provided at each corner of the cart 12. The legs 32cooperate with the horizontal support members 29 and the verticalsupport posts 27 to define a supporting framework for the awning supportsections 18. The side panels 28 extend between the legs 32 and thevertical support posts 27, as illustrated.

As shown best in FIG. 2, a lower terminal section 36 of thecart-supporting leg 32 is upwardly spaced a distance D from a bottom ofthe wheels 30 (i.e., from the support surface), and is of a relativelysmaller size than the remainder of the leg 32. This smaller lowerterminal section 36 is adapted to be received within an enlarged upperterminal section 38 of a downwardly adjacent leg. Receipt of the lowerterminal section 36 by the upper terminal section 38 allows the carts tobe vertically stacked which is helpful in shipping and storing multiplecarts. The lower section 36 is upwardly spaced from the support surfaceto allow the wheels 30 to freely rotate and thereby propel or move thecart without interference from the legs 32.

Preferably, the overall length of the cart 12 is about 120 inches. Eachof the awning support sections 18 is about 36 inches, with about 18inches being between each of the forklift receiving channels 24.Preferably, the cart also has a width of about 36 inches and a verticalheight of about 34 inches. The usable height of the cart 12, which isgenerally equal to the vertical height of the side panels 28 of theawning support sections 18, is about 20 inches.

With reference to FIGS. 4-7, one of the awning support plates 14 of thepresent invention is shown. With particular reference to FIG. 5, theawning support plate 14 is shown to define a wave-like surface. Thewave-like surface provides a series of lower sections 42 and uppersections 44, the lower and upper sections 42, 44 being connected byintermediate ramping members 46, as illustrated. Hence, a repeatingpattern of lower section 42, ramping section 46, upper section 44, andramping section 46 is provided by the support plate 14. Lower braces 48connect the ramping members 46 with the lower sections 42, while upperbraces 49 connect the ramping members to the upper sections 44.

The awning support plates 14 are designed to alternatively stack ornest. As illustrated in FIG. 3, when the support plates 14 are in thestacked configuration the lower sections 42 of one support plate abutand rest on the upper sections 44 of a downwardly adjacent awningsupport plate. Likewise, the upper sections 44 of an awning supportplate abut and support the lower sections 42 of an upwardly adjacentawning support plate. As such, the vertically adjacent and stackedawning support plates 14 define a series of elongated awning-receivingchannels 50.

The awning-receiving channels 50 are designed to be slightly larger thanthe awnings 10 which are placed therein. Sizing of the elongatedchannels 50 as such allows the awnings 10 to be freely and slidablymovable within the channels

The support plates are preferably placed in a nested configuration forreturn shipment to the awning manufacturer or for prolonged storage bythe awning manufacturer. When nested, the lower sections 42 of theawning support plates are in contact with the lower braces 48 between adownwardly adjacent lower section 42 and ramping section 46. Likewise,the upper braces 49 are in contact with an upper surface of a downwardlyadjacent support plate upper section 44.

The awning support plates 14 are vertically stacked on the supportsections 18 of the cart, leaving the open section 20 therebetween. Theawnings 10 typically have a length which is greater than that of thecart 12. Therefore, the ends 17 of the awnings 10 extend or project fromthe elongated channels 50 defined by the awning support plates in anunsupported or cantilever fashion, as illustrated. The projecting orcantilever ends 17 of the awnings are covered by the pair of awning endbags 16. The end bags 16 limit longitudinal movement of the awnings, andthereby prevent the awnings from sliding out of the elongated channels50 during transport.

The awning end bags 16 provided by the present invention comprise afabric main section 52 and a series of straps The straps 54 are providedon opposite sides of the main section 52 and connect to an adjacentvertical leg 32 provided by the cart 12. Preferably, the straps 54 arereleasably locked to the vertical legs 32. Typically, ends of the straps54 will be locked to the legs 32 by the manufacturer or shipper toprevent the end bags 16 from being accidentally misplaced by theretailer. Upon return of the empty cart to the manufacturer, the endbags 16 are released or unlocked from the legs to ease re-loading of thecart. Length adjustment means 56 are provided by the straps 54 to ensurea close supporting fit between the main section 52 and the awning ends17. The length adjustment means 56 also allow the end bags 16 to beremoved from the awning ends 17, and thereby provide access to theawnings without unlocking the straps 54 from the legs 32.

The main fabric section 52 of the awning end bags 16 is designed anddimensioned to generally match the profile of the cantilever orprojecting ends 17 of the awnings 10 and, therefore, provides a snug andcontinuous fit for the awning ends 17. The main section 52, which ispreferably made of a durable fabric such as canvas, overlies andencloses the projecting ends 17 of the awnings, and helps to preventdamage to the awning ends 17 during shipment and subsequent storage. Asshown best in FIG. 1, when the extending straps 54 are drawn tight, theawning end bag 16 engages the cantilever ends 17, and limits orotherwise prevents the awnings 10 from moving longitudinally.

Use of the aforementioned packaging system will be described hereafterwith reference to the foregoing description and drawings. Starting withan empty cart 12, an awning support plate 14 is placed on the bottompanel 26 of each awning support section 18. The awning support plates 14are positioned and retained between the side panels 28, the cartsupporting legs 32, and the vertical support posts 27.

With the pair of awning support plates 14 (one for each awning supportsection 18) positioned on the cart 12, awnings 10 are placed on thesupport plates 14 in contact with the bottom section 42 thereof. Theawnings 10 are received by and extend between the awning support plates14. If the awnings are long enough, the ends 17 extend or project fromthe awning support plates 14 in an unsupported or cantilever fashion.Thereafter, another or second awning support plate 14 is stacked on theexisting plate and awnings 10 are placed on the second support plate 14in contact with the lower section 42 thereof. The process is repeateduntil the cart 12 is full.

As mentioned hereinbefore, the lower sections 42 and adjacent rampingmembers 46 of one support plate 14 cooperate with upper sections 44 andadjacent ramping members 46 of a vertically adjacent support plate todefine the elongated awning-receiving channels 50. Also, the uppersurfaces of an upper section 44 vertically support and engage lowersurfaces of a lower section 42 provided by a vertically adjacent supportplate 14. The elongated channels 50 are preferably larger in diameterthan the awnings 10, thereby allowing any particular awning to be freelyand slidably removed from the array of awnings within the system.

Once the desired number of awnings 10 are placed on the cart 12, themain section 52 of the awning end bag 16 is fitted or placed over thecantilever ends 17 of the awnings and the removable straps 54 areattached to the legs 32. The length adjustment means 56 are adjusted toforce the main section 52 to cover or enclose the cantilever ends 17 ofthe awnings 10, as illustrated in FIG. 1. As stated hereinbefore, themain section 52 covers and protects the ends 17 of the awnings 10 duringshipment and prevents lengthwise or longitudinal movement of theawnings.

If more than one cart 12 is to be shipped or stored, the carts can bevertically stacked upon one another to reduce the floor space requiredfor shipment and storage. One cart is lifted, by a forklift or the like,and lowered on a downwardly adjacent supporting cart such that thesmaller terminal sections 36 of the lifted cart legs 32 are received bythe enlarged upper terminal section 38 of the lower cart legs. Thewheels of the lifted cart are vertically adjacent or above the awningscarried by the lower cart.

While the preferred embodiment of the present invention is shown anddescribed herein, it is to be understood that the same is not so limitedbut shall cover and include any and all modifications thereof which fallwithin the purview of the invention as defined by the claims appendedhereto.

What is claimed is:
 1. A returnable and reusable packaging and storingsystem for elongated tubular members, said system comprising a pluralityof support plates and means for movably supporting said support plates,said support plates cooperating to define a series of elongated,generally horizontal channels, each of said channels surrounding andsupporting an elongated tubular member, said elongated channels beingdimensioned to allow the tubular members to be slidably removedtherefrom and inserted therein without interference from adjacenttubular members and to permit ends of said tubular members to projectfrom the channels in a cantilever fashion, wherein said supporting meanscomprises a cart having a pair of support plate supporting sections andan open section intermediate the supporting sections, each of saidsupporting sections having a plurality of support plates stackedthereon, thereby forming a pair of stacks of support plates which areseparated by the open section, said elongated channels defined by onestack of support plates are generally coaxially aligned with theelongated channels defined by the other stack of support plates, whereincoaxially aligned channels receive and support spaced-apart sections ofone of the elongated tubular members.
 2. A returnable and reusablepackaging and storing system for elongated tubular members according toclaim 1, wherein each of said support plates comprise a series of upperand lower surface members which are interconnected by ramping surfacemembers, the lower surface members of the support plates resting uponthe upper surface members of a downwardly adjacent support plate.
 3. Areturnable and reusable packaging and storing system for elongatedtubular members according to claim 2, wherein the upper surface memberand a first pair of ramping members of a first support plate cooperatewith the lower surface member and a second pair of ramping members of asecond support plate to define one of the elongated channels.
 4. Areturnable and reusable packaging and storing system for elongatedtubular members according to claim 3, wherein each support plateincludes reinforcement braces, said braces being provided between theupper surface members and the ramping members and between the lowersurface members and the ramping members.
 5. A returnable and reusablepackaging and storing system for elongated tubular members according toclaim 1, wherein the cart includes means for aligning and retaining thesupport plates.
 6. A returnable and reusable packaging and storingsystem for elongated tubular members according to claim 5, wherein thealigning and retaining means comprise a plurality of posts.
 7. Areturnable and reusable packaging and storing system for elongatedtubular members, said system comprising:a plurality of support plateswhich cooperate to define a series of elongated, generally parallelchannels, each of said channels receiving and supporting an elongatedtubular member, wherein the channels are sized and dimensioned to allowthe tubular members to be slidably inserted therein and removedtherefrom without interference from adjacent tubular members; a movablecart upon which the support plates are stacked, said cart includingmeans for positioning and retaining said support plates thereon, saidcart comprising a pair of support sections and an open sectionintermediate the support sections, each of said support sections havinga plurality of support plates stacked thereon, thereby forming a pair ofstacks of support plates which are separated by the open section, saidelongated channels of one stack of support plates are generallycoaxially aligned with the elongated channels in the other stack ofsupport plates, wherein coaxially aligned channels receive and supportspaced-apart sections of one elongated tubular member.
 8. A returnableand reusable packaging and storing system for elongated tubular membersaccording to claim 7, wherein elongated tubular members are receivedwithin the elongated channels and the cart is sized such that ends ofthe tubular members project or extend therefrom in a cantilever fashion,said system further comprising means for protecting the cantileveredends of the tubular members.
 9. A returnable and reusable packaging andstoring system for elongated tubular members according to claim 8,wherein said protecting means comprises an end bag, said end bagincluding a main body portion and a plurality of cart-engaging straps,said straps being adjustably attached to the cart to allow the main bodyof the end bag to snugly engage the tubular members, said main bodyprotecting the ends of the tubular members and generally preventing saidtubular members from moving longitudinally.
 10. A returnable andreusable packaging and storing system for elongated tubular membersaccording to claim 8, wherein said protecting means comprises an endbag, said end bag including a fabric main body and a plurality ofcart-engaging straps, said straps being adjustable to allow the fabricmain section to snugly engage the cantilever ends of the tubularmembers.
 11. A returnable and reusable packaging and storing system forelongated tubular members said system comprising a plurality of supportplates and means for movably supporting said support plates, saidsupport plates cooperating to define a series of elongated, generallyhorizontal channels, each of said channels surrounding and supporting anelongated tubular member, said channels being dimensioned to allow thetubular members to be slidably removed therefrom and inserted thereinwithout interference from adjacent tubular members and to permit ends ofsaid tubular members to project from said elongated channels in acantilever fashion, wherein said supporting means comprises a carthaving a pair of support plate supporting sections and an open sectionintermediate the supporting sections, each of said supporting sectionshaving a plurality of support plates stacked thereon to thereby form apair of stacks of support plates which are separated from each other bythe open section, said system including means for protecting thecantilevered ends of the tubular members and for preventing longitudinalmovement of said tubular members.
 12. A returnable and reusablepackaging and storing system for elongated tubular members according toclaim 11, wherein said protecting means comprises an end bag, said endbag including a main body portion and a plurality of cart-engagingstraps, said straps being adjustably attached to the cart to allow themain body of the end bag to snugly engage the tubular members, said mainbody protecting the ends of the tubular members and generally preventingsaid tubular members from moving longitudinally.